System and method of guard rail installation and alteration

ABSTRACT

A system and method for installing or altering a guardrail section on site is provided, as is a method for installing or altering guardrail sections on site. The system comprises a punch press comprising a throat for receiving a guardrail section therein comprising a punch suitable for punching a hole through the guardrail section and a die capable of receiving the punch after passage through the guardrail section. An articulating arm is attached to the punch press and a mobile device is attached to the articulating arm wherein the mobile device is capable of manipulating the articulating arm to place the punch press in engaging relationship with the guardrail section.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to pending U.S. Provisional Patent Application No. 62/474.878 filed on Mar. 22, 2017, which is incorporated herein by reference.

BACKGROUND

The instant invention is related to an improved system and method for installing new guardrail and, more specifically, to an improved system and method for altering previously installed guardrail that eliminates the need for replacement of used guardrail that would otherwise fail to conform to new guardrail standards. The invention prevents the waste of perfectly suitable materials that would otherwise be discarded when necessary roadway alterations would otherwise require new guardrail to comply with updated codes.

Guardrails are common throughout the world as a barrier to prohibit vehicle roadway departures. In the United States of America, guardrails are highly regulated by various state and federal agencies, all having the goal of increasing safety to protect life and property. Further details are available at http://www.aashtotf13.org. A critical aspect of these safety materials is related to the flexibility of the guardrail after impact. If the guardrail system is overly rigid, the impact by an out-of-control vehicle is manifested in the vehicle and passengers leading to more damage and injury. If the guardrail is insufficiently rigid, it fails to prohibit an out-of-control vehicle from exiting the roadway, thus increasing the risk of injury and fatalities. Through much research, it has been verified that the rigidity of guardrails may be further optimized to absorb energy upon impact thereby minimizing injury and damage to the vehicle, while providing a sufficient barrier to preventing roadway departure.

Under previous regulations, guardrail sections were required to be bolted together to form a ribbon, wherein the overlap of adjacent guardrails met at a post. Threaded members, such as bolts for securing a nut thereto, passed through mating voids of both overlapping guardrails, then through a void in a blockout and ultimately through a post. While this form of construction—with guardrail section overlaps being secured to a post—has been the standard for many decades, new research has determined that a more effective guardrail structure can be obtained by having the post secured to a single guardrail section, between the guardrail section overlaps, where the guardrail section overlaps are not directly supported. More information on this research can be found at https://static.tti.tamu.edu/conferences/tsc11/presentations/design/bligh.pdf slide 15 of 32. Whereas previous guardrail systems were installed with a post at every seam, new regulations specify improvements where the post is positioned between the overlap of adjacent guardrail sections. More information on this can be found at https://docs.lib.purdue.edu/cgi/viewcontent.cgi!referer=https://www.google.com/&httpsr edir=1&article=4042&context=roadschool, slides 5 and 6.

This change in regulation has created a conundrum for those in the industry of guardrail installation. Regulations still prohibit heating or drilling of guardrail sections so the guardrail must be removed and replaced to achieve the new standard. See https://safety.fhwa dot.gov/roadway_dept/countermeasures/faqs/qa_bttabr.cfm#btcc10 question 10. One alternative for dealing with this conundrum is to remove the guardrail for transport to a stamping facility for stamping of new voids, wherein the new voids are positioned to accommodate the new placement of the post behind the guardrail. This is, however, an extremely cost prohibitive and labor-intensive practice.

The present invention provides a method, and apparatus, for installing or altering guardrail that does not require removing the guardrail from the site, thereby significantly enhancing the efficiency of guardrail alteration.

SUMMARY OF THE INVENTION

It is an object of the invention to provide an improved method for the installation or alteration of guardrail. A particular feature of the invention is the ability to alter installed guardrail without removing the guardrail from the roadside worksite, thereby significantly increasing the efficiency of guardrail alteration.

An additional feature provided by the present invention is the invention's ability to allow state Departments of Transportation to maintain the control over the identity of materials that the state owns and is charged with managing. As discussed above, guardrail barrier construction materials are highly regulated. Highway guardrail system elements, such as guardrail panels and posts, require traceable documentation verifying the metallurgical composition, corrosion resistant coating and domestic origin of said materials. This data is tracked with ‘heat numbers’ kept on file with DOTs and highway contractors, and are issued by steel manufacturing facilities. Heat numbers are specific to highway construction regulations, where the contractors have purchased traceable materials according to DOT specifications. Thus, it is crucial that State DOTs can trace installed materials to the factory. However, once guardrail is removed, in order to be taken back to a stamping facility, this paperwork trail for materials verification is at risk of being broken. The flexibility afforded State DOT officers by the present invention, allows a State's guardrail materials to remain in-place, remaining in full supervision of a State's Department of Transportation.

An additional feature of the invention is the significant reduction of construction worker exposure to active roadway traffic. Without the system and method of the invention, 10-12 bolt/nut assemblies (approximately 1,500-3,000 sets per mile) must be removed and subsequently reinstalled or replaced with new hardware. This hardware is often rather difficult to disassemble. The invention allows for the modification of in-service guardrail while greatly reducing the required replacement of guardrail hardware from 10-12 units to only 2-4 bolt/nut units per panel—a reduction of up to 80%. This results in much reduced work and as roadside guardrail modification is needed, the present invention will reduce the exposure of workers to the hazards of roadway construction zone traffic.

The above advantage also leads to an additional feature of the invention—nearly all threaded fasteners remain in place. As described above, the invention allows approximately 80% of threaded bolt/nut and hardware assemblies to remain in place and in service and thus out of waste streams.

Another particular feature of the invention is the ability to form voids in guardrail at the site of installation, thereby providing an alternate installation method. This feature provides tremendous efficiency advantages over current alteration methods, saving both time and money.

These and other embodiments, as will be realized, are provided in a system for installing or altering a guardrail section on site. More specifically, the system comprises a punch press comprising a throat for receiving a guardrail section therein comprising a punch suitable for punching a hole through the guardrail section and a die capable of receiving the punch after passage through the guardrail section. A fixed or articulated arm is used to suspend or hold the punch press, and a mobile device is attached to the arm, wherein the mobile device is capable of manipulating the arm to place the punch press for engaging the guardrail section. In an alternative embodiment, the articulating arm may be eliminated and the punch press is connected directly to the mobile device.

Yet another embodiment is provided in a method for installing or altering a guardrail section on site. The method comprises: providing a punch press comprising a throat for receiving a guardrail section therein, a punch suitable for punching a hole through the guardrail section and a die capable of receiving the punch after passage through the guardrail section. A fixed or articulating arm is optionally attached to the punch press. A mobile device is attached to the arm or directly to the punch press and capable of placing the punch press in engaging relationship with the guardrail section.

The method includes moving the mobile device to a position with the throat over the guardrail section between overlap post, with the guardrail section attached to the overlap post, wherein the punch press is manipulated to position where the guardrail is positioned between the punch and die. The punch is activated to form at least one void in the guardrail section. The punch press is then removed from the guardrail section. A span post is installed wherein the span post has a post void aligned with the guardrail void. A threaded member is then inserted through the guardrail void and the support post.

More specifically, the invention provides a system for installing or altering a guardrail section on site comprising: a punch press comprising: a throat for receiving a guardrail section therein, a punch suitable for punching a hole through said guardrail section, and a die capable of receiving said punch after passage through said guardrail section: and a mobile device attached to said punch press and capable of placing said punch press in engaging relationship with said guardrail section.

The invention may optionally provide an articulating arm attached between said punch press and said mobile device, wherein said articulating arm is capable of placing said punch press in engaging relationship with said guardrail section. The invention may be optionally provisioned wherein said punch and said die are removable from said punch press. The invention may optionally provide an adjustment element for said press. The invention may optionally provide at least one switch. Or, the invention may optionally provide two switches arranged such that both must be activated by a user prior to activation of said punch. And the invention may be optionally provisioned where said articulating arm is attached to said punch press in a position selected from parallel to said punch and perpendicular to said punch.

The invention also provides a method for installing or altering a guardrail section on site comprising: providing a punch press comprising: a throat for receiving a guardrail section therein, a punch suitable for punching a hole through said guardrail section, and a die capable of receiving said punch after passage through said guardrail section; providing a mobile device attached to said punch press capable of placing said punch press in an engaging relationship with said guardrail section; moving said mobile device to position said throat over said guardrail section, wherein said guardrail is positioned between said punch and said die; and activating said punch to form at least one guardrail void in said guardrail section.

The method invention may optionally include the step of installing a span post wherein said span post has a post void aligned with said guardrail void. The method invention may optionally include the step of positioning said punch press over said guardrail section, wherein said guardrail section is positioned between overlap posts, with said guardrail section attached to said overlap posts. The method invention may optionally include the step of inserting a threaded member through said post void and said guardrail void. The method invention may optionally include the step of providing an articulating arm attached between said punch press and said mobile device, wherein said articulating arm is capable of placing said punch press in an engaging relationship with said guardrail section. The method invention may optionally include provisions whereby said punch and said die are removable from said punch press. The method invention may optionally include provisions whereby said punch press further comprises an adjustment element.

The method invention may optionally include provisions whereby at least one switch is used. Or, the method invention may optionally Include provisions whereby two switches are used and arranged such that both must be activated by a user prior to activation of said punch. And the method invention may optionally include provisions whereby said articulating arm is attached to said punch press in a position selected from parallel to said punch and perpendicular to said punch.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a conventional guardrail system.

FIG. 2 is a perspective view of a guardrail envisioned for use with the instant invention.

FIG. 3 is a side view of an embodiment of the Invention.

FIG. 4 is a side view of an embodiment of the Invention In use.

FIG. 5 is a perspective view of an embodiment of the invention in use.

DETAILED DESCRIPTION OF INVENTION

The present invention is an improved system and method of installation or alteration of guardrail. More specifically, the present invention provides a system and method of alteration of an installed guardrail system that does not require removing the guardrail that is already installed (on-site), thereby eliminating the transport or replacement thereof.

A particular advantage of the instant invention is the minimization of environmental impact when changing from the use of overlap guardrail post spacing to mid-splice post spacing. Millions of feet of guardrail can be retrofitted and allowed to remain in service as opposed to being removed due to not having preexisting mid-splice through-bolt holes. Furthermore, the used guardrail and the vast majority of highway guardrail hardware would not have removed, transported and then handled In scrap yards and waste dumps.

This can be Important from an environmental standpoint because most guardrail is manufactured with galvanized metal. Galvanization includes the application of a zinc coating, which is a mild toxin, so the instant Invention prevents large amounts of toxic waste from being buried in landfills. The production of new guardrail is reduced. In addition, with new guardrail, the zinc coating must oxidize first, forming a patina, in order to be corrosion resistant. If the pre-existing guardrail, which has already oxidized, is therefore allowed to stay in service, the additional zinc oxide that is shed during the oxidization process is also minimized.

The invention will be described with reference to the figures, which form an integral, non-limiting, component of the disclosure. Throughout the specification similar elements will be numbered accordingly.

A conventional guardrail system is illustrated in FIG. 1 wherein adjacent guardrail sections, 10, are illustrated as being overlapped with at least one threaded member 12 extending through both guardrail sections and into a supporting post 14. Each panel overlap occurs at an overlap post. Generally there are three backing posts 14 engaging each 13.5-foot panel (section) of W-beam guardrail. And there are 5 backing posts engaging each 26-foot section. Each post 14 must have at least one through-bolt passing through a void, which is preferably elongated, in the guardrail section 10, and thus into the flange of the supporting post 14. In many cases, a blockout (not pictured) is positioned between the guardrail sections and the supporting posts, and a number of splice bolts (not pictured) are also used to hold two sections of guardrail together at the splices.

An improved guardrail system is illustrated in FIG. 2, wherein adjacent w-beam guardrail sections, 10, are illustrated as being overlapped at an overlap region 16 with at least one threaded member 12 extending through both w-beam guardrail sections within the overlap region 16. The overlap region 16 is spanned between the supporting posts 18.

A particular feature of the present invention is the ability to form the voids (holes) in a w-beam guardrail section in the center of the trough formed where the middle of the wave meets the post block-out, for attachment to a supporting post 18 without removal of the guardrail section from the supporting posts prior to formation of the void in the guardrail. More specifically, the present invention provides the ability to form the voids in a guardrail section for attachment to a supporting post without removal of the guardrail section from the site and preferably prior to removal of either the guardrail section from the supporting posts. That is to say, the invention allows for forming the voids necessary to install connectors, such as threaded members 12, while the guardrail is already in place and remains In place. This avoids the prior art method of having to remove the guardrail sections then transport to another location for forming the voids. In this manner, the voids are formed prior to the removal and the subsequent resetting of the supporting posts.

An embodiment of the invention is illustrated with reference to FIG. 3, where a w-beam guardrail section 22 which is to be punched is received within the throat 23 of a punch press 24. An adjustment element 26 is attached to the punch press to reversibly fix the distance 28 between the inserted edge 29 of the guardrail section and the punch 30. The punch mates with a die 32 on the reverse side of inserted edge 29 to form a cold press void (hole) in the guardrail section 22.

The punch press 24 is attached to a fixed or articulating arm 34 which is attached to a mobile device 36 such as a tractor, backhoe, excavator, skid steer, supporting truck or the like. In one embodiment, the articulating arm 34 is attached to the punch press in a position that is perpendicular to the punch. In other embodiments, articulating arm 34 may be suspended In a position 45 degrees away from mobile device 38. And in another embodiment, articulating arm 34 is attached to the punch press 24 in a position that is parallel to the punch. Attachment parallel to the punch is preferable as this facilitates rotation of the punch press for punching the guardrail from the top or bottom, which limits the requirement for the throat depth.

In operation, a punch actuator 38 persuades the punch towards the die with sufficient force to form a clean puncture through the guardrail to form the void. With conventional guardrail, a force of about 15 to 50 tons is sufficient. The punch actuator 38 is preferably hydraulically controlled and preferably coupled to the hydraulic system of mobile device 35. One or more handles 40 allow the operator to manipulate the punch press for fine adjustment of the location of the void.

As an optional safety feature, one or more switches 42 preferably on each handle 40 may be used, wherein at least one switch 42 must be engaged before the punch will activate. In a preferred embodiment, only one switch 42 is used. Whereas, in another embodiment, two switches 42 are used to increase safety in use of the invention. By requiring both switches 42 to be engaged simultaneously, the operator must have a hand on each switch, thereby insuring the operator cannot inadvertently insert a hand or finger between the punch and guardrail or guardrail and die.

It is preferable that the punch 30 and die 32 be removable and replaceable as repeated use of the punch and die results in wear, thereby decreasing the quality of the void formed thereby.

FIG. 4 further illustrates an embodiment of invention where mobile guardrail punch 44 is provided and mobile device 50 is provided and moved to position punch press 24 over guardrail section 22. Mobile device 50 can be a tractor, backhoe, excavator, skid steer, supporting truck, bobcat or the like. Articulating arm 52 is used in this embodiment to suspend punch press 24 over the guardrail so that an operator can position punch press 24 in the correct location to punch the guardrail 22. An operator grasps handles 40 in this embodiment to place punch press 24 in the proper horizontal and vertical location and alignment with guardrail section 22. Once in place, adjustment element 26 can be adjusted If needed to place and hold punch press 24 firmly in the correct location.

FIG. 5 further illustrates an embodiment of the mobile guardrail punch 44, where a w-beam guardrail section 22 is received within the throat of punch press 24. Here void 46 has been formed on edge 29 of guardrail section 22. Adjustment element 26 has been adjusted and placed accordingly to hold punch press 24 firmly in place. An articulating arm, as pictured in FIG. 4, would normally be affixed to bracket 48 to suspend or hold press 24 in place.

In normal operation, an operator grasps handles 40 to place punch press 24 in the proper horizontal and vertical location and alignment with section 22, where the punch 30 (not visible) is positioned to engage the edge 29 of guardrail 22. Then switch 42 is engaged to apply hydraulic pressure between punch 30 and die 32 (neither visible here), whereby punch actuator 38 activates to punch section 22 by engaging the punch and die to form the void 46 illustrated in section 22.

Although only one void 46 is pictured in FIG. 5, the invention can be used to punch multiple voids into a guardrail section as needed. In a preferred embodiment, the void 46 is an elongated or obround hole preferably between 1 inch and 3 inches in length. More preferably the void is 2.5 inches in length and ¾ inch in height on average.

The guardrail materials and sizes envisioned for use in conjunction with the invention are not particularly limited herein with the understanding that both are highly regulated and therefore it is preferable that the materials and sizes be sufficient to meet all necessary state and federal standards for use as a highway barrier without limit thereto.

A cold press as illustrated herein is desired because regulations and specifications generally prohibit heating or drilling of installed guardrail due to the impact of thermal expansion and contraction on the integrity of the structure or the metallurgy and/or temper of the steel, which can change the precise release dynamics of the guardrail ribbon from the post.

The invention has been described with reference to the preferred embodiments without limit thereto. Additional embodiments and improvements may be realized which are not specifically set forth herein but which are within the scope of the invention as more specifically set forth in the claims appended hereto. 

What is claimed is:
 1. A system for installing or altering a guardrail section on site comprising: a punch press comprising: a throat for receiving a guardrail section therein, a punch suitable for punching a hole through said guardrail section, and a die capable of receiving said punch after passage through said guardrail section; and a mobile device attached to said punch press and capable of placing said punch press in engaging relationship with said guardrail section.
 2. The system for installing or altering a guardrail section on site of claim 1 further comprising an articulating arm attached between said punch press and said mobile device, wherein said articulating arm is capable of placing said punch press in engaging relationship with said guardrail section.
 3. The system for installing or altering a guardrail section on site of claim 1 wherein said punch and said die are removable from said punch press.
 4. The system for installing or altering a guardrail section on site of claim 1 wherein said punch press further comprises an adjustment element.
 5. The system for installing or altering a guardrail section on site of claim 1 wherein said punch press comprises at least one switch.
 6. The system for installing or altering a guardrail section on site of claim 1 wherein said punch press comprises two switches arranged such that both must be activated by a user prior to activation of said punch.
 7. The system for installing or altering a guardrail section on site of claim 2 wherein said articulating arm is attached to said punch press in a position selected from parallel to said punch and perpendicular to said punch.
 8. A method for installing or altering a guardrail section on site comprising: providing a punch press comprising: a throat for receiving a guardrail section therein, a punch suitable for punching a hole through said guardrail section, and a die capable of receiving said punch after passage through said guardrail section; providing a mobile device attached to said punch press capable of placing said punch press in an engaging relationship with said guardrail section; moving said mobile device to position said throat over said guardrail section, wherein said guardrail is positioned between said punch and said die; and activating said punch to form at least one guardrail void in said guardrail section.
 9. The method for installing or altering a guardrail section on site of claim 8 further comprising the step of installing a span post wherein said span post has a post void aligned with said guardrail void.
 10. The method for installing or altering a guardrail section on site of claim 8 further comprising the step of positioning said punch press over said guardrail section, wherein said guardrail section is positioned between overlap posts, with said guardrail section attached to said overlap posts.
 11. The method for installing or altering a guardrail section on site of claim 8 further comprising the step of inserting a threaded member through said post void and said guardrail void.
 12. The method for installing or altering a guardrail section on site of claim 8 further comprising the step of providing an articulating arm attached between said punch press and said mobile device, wherein said articulating arm is capable of placing said punch press in an engaging relationship with said guardrail section.
 13. The method for installing or altering a guardrail section on site of claim 8 wherein said punch and said die are removable from said punch press.
 14. The method for installing or altering a guardrail section on site of claim 8 wherein said punch press further comprises an adjustment element.
 15. The method for installing or altering a guardrail section on site of claim 8 wherein said punch press comprises at least one switch.
 18. The method for installing or altering a guardrail section on site of claim 8 wherein said punch press comprises two switches arranged such that both must be activated by a user prior to activation of said punch.
 17. The method for installing or altering a guardrail section on site of claim 8 wherein said articulating arm is attached to said punch press in a position selected from parallel to said punch and perpendicular to said punch. 